Subaru Liberty 1991 Repair Service Manual

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🏷️ Basic Information Identification Make: Subaru Model: Liberty Year: 1991 Market Designation: Global (known as Legacy in most markets outside Australia) Codes Chassis Codes: BC3, BC5, BC6, BC7, BC8, BD2,...

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Type: Car

Vendor:

Sku: 392399

Tags: 1991 Car Cars Liberty Misc Subaru

Product variants

Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Liberty

Year:

Market Designation:

Global (known as Legacy in most markets outside Australia)

Codes

Chassis Codes:

BC3, BC5, BC6, BC7, BC8, BD2, BD3, BD4, BD5, BD6, BD7, BD8, BF3, BF5, BF6, BF7, BF8 (specific codes depend on body style and engine)

👋 Introduction

Market Position

Segment:

Mid-size sedan/wagon, often competing in the AWD-focused market.

Target Audience:

Drivers seeking reliable, all-weather capability and a unique driving experience.

Competitive Analysis

Competitors 1991:

Toyota Camry, Honda Accord, Mazda 626, Nissan Maxima.

Key Features

Feature 1:

Symmetrical All-Wheel Drive (AWD) as standard on most variants.

Feature 2:

Horizontally opposed 'Boxer' engines known for low center of gravity and smooth operation.

Feature 3:

Durable construction and reputation for longevity.

Feature 4:

Comfortable ride quality and practical interior space.

📋 Manual Details

Coverage Areas

Coverage:

Comprehensive repair and service information for the 1991 Subaru Liberty (Legacy).

Page Count

Page Count:

Estimated 1000+ pages (typical for a complete factory service manual)

Manual Type

Type:

Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, diagnosis, repair for all powertrain variants.

Engine Management:

Fuel injection system (MPI), ignition system, emissions control, sensor diagnosis, ECU operation.

Transmission:

Manual and automatic transmission service, repair, diagnosis, torque converter, clutches, gearsets.

Drivetrain:

All-Wheel Drive (AWD) system, viscous coupling unit (VCU), differentials, drive shafts, CV joints.

Suspension:

Front and rear suspension components, struts, springs, bushings, alignment procedures.

Steering:

Power steering system, pump, rack and pinion, steering column, tie rods.

Brakes:

Front and rear brake systems (disc/drum or disc/disc), ABS (Anti-lock Braking System) diagnosis and repair, brake fluid, lines, calipers, master cylinder.

Electrical System:

Complete automotive electrical schematics, wiring diagrams, battery, charging system, starter, lighting, horn, wipers, power accessories.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system service, refrigerant handling, components, diagnosis.

Body Exterior:

Body panel removal and installation, doors, hood, trunk, bumpers, glass, seals, body repair procedures.

Body Interior:

Interior trim removal and installation, seats, dashboard, door panels, headliner, safety restraints.

Procedures Included

Maintenance:

Scheduled maintenance procedures, fluid changes, filter replacements, lubrication.

Troubleshooting:

Diagnostic flowcharts and symptom-based troubleshooting for all major systems.

Repair:

Detailed step-by-step repair instructions for all components and systems.

Overhaul:

Complete engine and transmission overhaul procedures.

Diagnostics:

On-board diagnostics (OBD-I) information, sensor data interpretation, fault code lookup.

Wiring Diagrams:

Comprehensive electrical wiring schematics for all vehicle circuits.

Technical Depth

Depth:

Factory-level technical depth, suitable for professional technicians and advanced DIY enthusiasts.

Diagnostic Tools:

Recommendations for specialized tools and diagnostic equipment.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Searchable text content for easy navigation and information retrieval.

Print Quality

Resolution:

High-resolution digital reproduction ensuring clarity of text and diagrams.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

EJ22 (most common)

Configuration:

2.2L SOHC 16-valve Flat-4 (Boxer)

Bore X Stroke:

92.0 mm x 80.0 mm

Compression Ratio:

9.5:1

Horsepower:

110 hp @ 5200 rpm

Torque:

137 lb-ft @ 4400 rpm

Performance

Engine Options:

Also available: 1.8L EJ18, 2.0L EJ20 (various versions including turbo for GT/GTS variants).

Fuel System

Injection Type:

Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (Octane Rating: 87 Recommended)

Ignition System:

Electronic Ignition (Distributorless Ignition System - DIS on some models).

🔧 Transmission

Standard

Type:

5-speed Manual Transmission

Optional

Type:

4-speed Automatic Transmission

Features

AWD Engagement:

Full-time Symmetrical All-Wheel Drive (manual transmission models typically have viscous coupling centre diff).

Automatic Features:

Electronically controlled, available with viscous coupling AWD.

Fluid Specifications

Manual Fluid:

Subaru Extra-S Gear Oil GL-5 75W-90 or equivalent.

Automatic Fluid:

Dexron III/Mercon ATF or equivalent.

📐 Dimensions

Exterior

Wheelbase:

Approx. 2620 mm (103.1 in)

Length:

Approx. 4640 mm (182.7 in) (Sedan)

Width:

Approx. 1700 mm (66.9 in)

Height:

Approx. 1400 mm (55.1 in) (Sedan)

Weights

Curb Weight:

Approx. 1350 - 1450 kg (depending on trim and drivetrain)

🛡️ Safety Features

Ratings

NHTSA Ratings:

Not extensively tested by modern NHTSA standards; era-appropriate safety features.

Active Features

Optional Anti-lock Braking System (ABS) on some models.

Passive Features

Airbags:

Driver's side airbag standard on most models for this year. Passenger airbag not typically available.

Seatbelts:

3-point front seatbelts, 2-point rear seatbelts (may have 3-point in rear depending on market).

Rollover Protection:

Reinforced roof structure inherent to Subaru design.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/Cassette stereo, with optional CD player on higher trims. Speaker configurations vary by body style.

Controls:

Manual controls for climate and audio systems.

Driver Assistance

Cruise Control:

Available on most models.

Other Features:

Power windows, power locks, power mirrors, remote trunk release (depending on trim).

Connectivity

Connectivity Options:

N/A (no integrated Bluetooth or smartphone connectivity for this era).

🔧 Maintenance

Service Intervals

Oil Change:

Every 3,000-5,000 miles (5,000-8,000 km) or 6 months, whichever comes first.

Air Filter:

Inspect every 15,000 miles (24,000 km), replace as needed.

Spark Plugs:

Replace every 30,000 miles (48,000 km).

Timing Belt:

Replace every 60,000 miles (96,000 km) or 5 years (critical maintenance item for EJ engines).

Fluid Specifications

Engine Oil:

API SG/SH, SAE 10W-30 or 10W-40. Capacity: 4.5 US quarts (4.2 liters) with filter.

Coolant:

Subaru Genuine Coolant or equivalent (50/50 mix with distilled water). Capacity: Approx. 7.5 US quarts (7.1 liters).

Brake Fluid:

DOT 3 or DOT 4.

Power Steering Fluid:

ATF Dexron II/III or Subaru Genuine Power Steering Fluid.

Known Issues

Issue 1:

Head Gasket Leaks: Common on EJ series engines, especially older naturally aspirated versions. The manual will detail replacement procedures.

Issue 2:

Viscous Coupling Unit (VCU) Failure: Can cause binding or uneven drivetrain operation. Manual will cover diagnosis and potential replacement.

Issue 3:

Radiator Leaks/Corrosion: Especially aluminum radiators of this era. Manual will cover coolant system service and component replacement.

Issue 4:

Suspension Wear: Bushings, ball joints, and struts can wear over time. Detailed inspection and replacement procedures are covered.

Issue 5:

Rusting: Common in areas exposed to salt, particularly on body panels, frame rails, and exhaust systems. Manual provides body repair sections.

📚 Vehicle History

Brand Heritage

Heritage:

Subaru Corporation (formerly Fuji Heavy Industries) has a long history in aviation and automotive manufacturing, known for its AWD and Boxer engine technology.

Model Evolution

Generation Start:

The 1991 model year marks the introduction of the first generation of the Subaru Legacy (Liberty), replacing the older Subaru Leone.

Body Styles:

Available in sedan, wagon, and coupe (Brougham) body styles.

Performance Variants:

Introduction of the Liberty RS (Legacy GT/GT-Turbo) with turbocharged EJ20 engines and sport-tuned suspension.

Production

Production Period:

First Generation (BC/BF/BJ): 1989–1994.

🏆 Awards & Recognition

Recognitions

Car And Driver 1991:

Car and Driver recognized the Subaru Legacy (Liberty) in its '10Best' list for 1990 and 1991, highlighting its value, handling, and AWD system.

Motor Trend 1990:

MotorTrend Import Car of the Year nominee for 1990.